JP-7854935-B2 - Composite products of functional textile materials and methods for using them

JP7854935B2JP 7854935 B2JP7854935 B2JP 7854935B2JP-7854935-B2

Inventors

モンテス，ニコラス・ジョセフ
オリバー，コディ・ディー
ブロックウェイ，ランス・アール
ウォルサー，デビッド・シー

Assignees

ネルンボ・インコーポレイテッド

Dates

Publication Date: 20260507
Application Date: 20201211
Priority Date: 20200313

Claims (19)

A composite material including the top and bottom surfaces: (a) A t layer of the x layer of the material having one or more functional properties (wherein the t layer includes the uppermost layer including the top surface); (b) A b layer of the y layer of a material having one or more functional properties (wherein the A b layer includes the bottom layer including the bottom surface); and (c) B layer of the z layer of an insulating or structural material between the At layer of the x layer and the A b layer of the y layer, In that case, x, y, and z are the same or different in number of layers. The At layer and the Ab layer each contain a binderless ceramic material on a substrate. The composite product wherein the ceramic materials on each At layer and/or each Ab layer are the same or different, and are incorporated into performance outerwear clothing, medical bandages, medical casts, surgical gowns, filtering or separation media, pipe insulation, pipe protection, hospital flooring, absorbent textiles, protective masks, protective clothing, building textiles, or geotextiles.
(i) The binderless ceramic material is crystalline, or (ii) The ceramic material comprises a metal oxide, a hydrate of a metal oxide, a metal hydroxide, and/or a hydrate of a metal hydroxide, or (iii) The ceramic material comprises a metal hydroxide, and at least a portion of the metal hydroxide comprises a layered double hydroxide. The composite product described in claim 1.
The composite article according to either claim 1 or 2, wherein the ceramic is a nanostructured ceramic.
The composite article according to claim 1, wherein the substrate for at least one At layer and/or at least one Ab layer comprises a material selected from synthetic or natural textiles, metal mesh, metal screen, metal cloth, synthetic or natural polymer material or film, which is woven, non-woven, or knitted.
The composite article according to claim 1, wherein the substrate for at least one layer At and the substrate for at least one layer Ab , or the substrate for at least two layers At , or the substrate for at least two layers Ab , comprises different materials selected from synthetic or natural textiles, metal mesh, metal screen, metal cloth, synthetic or natural polymer materials or films, which are woven, non-woven, or knitted.
The composite article according to claim 1, wherein each A t and/or A b layer includes one or more functional properties selected from ice or condensate management, de-icing, frost protection, superhydrophobicity, superhydrophilicity, inhibition of microbial growth, corrosion resistance, electromagnetic modulation, thermal modulation, flame retardancy, breathability, dynamic wind resistance, color, absorption, barrier, maintenance properties, aesthetic properties, odor control, abrasion resistance, mechanical properties, surface friction, feel, durability, or a combination thereof.
(i) x and/or y are greater than 1, and each At and/or Ab layer has different functional characteristics from other At and/or Ab layers, or (ii) the uppermost layer including the top surface and the lowermost layer including the bottom surface have the same functional characteristics, or (iii) the uppermost layer including the top surface and the lowermost layer including the bottom surface have different functional characteristics. The composite product described in claim 5.
(i) at least one At layer and/or at least one Ab layer comprises a topcoat material that imparts one or more functional properties, and at least one functional property imparted by the topcoat material is superior to the same functional property imparted by the same topcoat material directly deposited on the same substrate without the ceramic material, or (ii) at least one At layer and/or at least one Ab layer comprises a topcoat material, and the ceramic material and the topcoat material synergistically impart one or more functional properties that are superior to the same functional properties imparted by either the ceramic material or the topcoat material independently deposited on the same substrate surface, or (iii) at least one At layer and/or at least one A The binderless ceramic material on layer b has a partially filled porous structure, and the voids in the ceramic material are partially filled with a second ceramic material or with molecules having a head group and a tail group, wherein the head group is selected from the group consisting of silane group, phosphonate group, phosphonic acid group, carboxylic acid group, alcohol group, hydroxide group, thiolate group, thiol group, ammonium group, and combinations thereof, and the tail group is selected from the group consisting of hydrocarbon group, fluorocarbon group, vinyl group, phenyl group, epoxide group, acrylic group, acrylate group, hydroxyl group, and combinations thereof. The composite product described in claim 1.
(i) Each B layer comprises one or more structural properties selected from thermal resistance, electrical resistance, structural support, mechanical padding, and fluid transport properties, or a combination thereof, or (ii) one or more B layers comprises a ceramic material selected from glass fiber, loose ceramics, and other inorganic materials. The composite product described in claim 1.
An insulating material or protective material for piping, comprising the laminated product described in claim 1, An insulating or protective material for piping, wherein one or more A t layers include hydrophobic or superhydrophobic functional properties, one or more B layers include thermal insulation, protection, or structural properties, and one or more A b layers include hydrophilic or superhydrophilic functional properties.
(i) The composite product surrounds the piping, The bottommost Ab layer is in contact with the piping, and the topmost At layer is in contact with the surrounding environment, and/or (ii) one or more At layers and/or one or more Ab layers comprise a ceramic-coated woven material, wherein the woven material is selected from stainless steel alloy woven material, carbon steel alloy woven material, aluminum alloy woven material, and textiles, and/or (iii) at least one B layer comprises a material selected from fiberglass, silicon carbide, ceramic fiber insulation, silicone or silicone foam, mineral wool, basalt, foamed glass, polyimide, calcium silicate, or silica. The pipe insulating material or pipe protective material according to claim 10.
A pipe surrounded by a pipe insulating material or pipe protective material according to any one of claims 10 and 11.
A textile material comprising the composite product described in claim 1, The textile material wherein one or more A t layers have hydrophobic or superhydrophobic functional properties, one or more B layers have thermal insulation, protective or structural properties, and one or more A b layers have hydrophilic or superhydrophilic functional properties.
(i) one or more At layers and/or one or more Ab layers are made of a woven material, the woven material being selected from textiles, polyamides, polyesters, polymer substrates or films, cellulosic materials, cotton, wool, stainless steel alloy woven materials, and aluminum alloy woven materials, or (ii) one or more At layers and/or one or more Ab layers are made of nylon or polyethylene terephthalate (PET), and/or (iii) one or more B layers are made of a material selected from polyesters, fleece, wool, feathers, down, and other mainly organic materials. The textile material according to claim 13.
A composite material including the top and bottom surfaces: (a) Layer A of the x layer of the material having one or more functional properties (wherein layer A includes the uppermost layer including the top surface, Each of the above A layers includes a binderless ceramic material on a substrate; and (b) a B layer of the z layer of an insulating or structural material (wherein the B layer includes the bottom layer including the bottom surface). In this case, x and z have the same or different number of layers, and the composite is incorporated into performance outerwear clothing, medical bandages, medical casts, surgical gowns, filtering or separation media, pipe insulation, pipe protection, hospital flooring, absorbent textiles, protective masks, protective clothing, building textiles, or geotextiles.
A composite material including the top and bottom surfaces: (a) an At layer of the x layer of a material containing one or more functional properties (where the At layer includes the uppermost layer including the top surface); and (b) an Ab layer of the y layer of a material containing one or more functional properties (where the Ab layer includes the lowermost layer including the bottom surface), In this case, the At layer and the Ab layer each contain a binderless ceramic material on the substrate. The ceramic material on the A t layer is different from the ceramic material on the A b layer. The composite product wherein x and y are the same or different and are incorporated into performance outerwear clothing, medical bandages, medical casts, surgical gowns, filtering or separating media, pipe insulation, pipe protection, hospital flooring, absorbent textiles, protective masks, protective clothing, building textiles, or geotextiles.
(i) The ceramic material is crystalline, (ii) The ceramic material comprises a metal oxide, a hydrate of a metal oxide, a metal hydroxide, and/or a hydrate of a metal hydroxide, (iii) The ceramic material contains a metal hydroxide, and at least a portion of the metal hydroxide contains a layered double hydroxide, and/or (iv) The ceramic is a nanostructured ceramic, The composite product according to claim 15 or 16.
(i) at least one A layer comprises a topcoat material that imparts one or more functional properties, and at least one functional property imparted by the topcoat material is superior to the same functional property imparted by the same topcoat material directly deposited on the same substrate without the ceramic material, or (ii) at least one A layer comprises a topcoat material, and the ceramic material and the topcoat material synergistically impart one or more functional properties that are superior to the same functional properties imparted by either the ceramic material or the topcoat material independently deposited on the same textile surface, or (iii) A binderless ceramic material on at least one layer A has a partially filled porous structure, wherein the voids in the ceramic material are partially filled with a second ceramic material or with molecules having head groups and tail groups, wherein the head groups are selected from the group consisting of silane groups, phosphonate groups, phosphonic acid groups, carboxylic acid groups, alcohol groups, hydroxide groups, thiolate groups, thiol groups, ammonium groups, and combinations thereof, and the tail groups are selected from the group consisting of hydrocarbon groups, fluorocarbon groups, vinyl groups, phenyl groups, epoxide groups, acrylic groups, acrylate groups, hydroxyl groups, and combinations thereof. The composite product according to claim 15.
(i) at least one At layer and/or at least one Ab layer comprises a topcoat material that imparts one or more functional properties, and at least one functional property imparted by the topcoat material is superior to the same functional property imparted by the same topcoat material directly deposited on the same substrate without the ceramic material, or (ii) at least one At layer and/or at least one Ab layer comprises a topcoat material, and the ceramic material and the topcoat material synergistically impart one or more functional properties that are superior to the same functional properties imparted by either the ceramic material or the topcoat material independently deposited on the same textile surface, or (iii) at least one At layer and/or at least one A The binderless ceramic material on layer b has a partially filled porous structure, and the voids in the ceramic material are partially filled with a second ceramic material or with molecules having a head group and a tail group, wherein the head group is selected from the group consisting of silane group, phosphonate group, phosphonic acid group, carboxylic acid group, alcohol group, hydroxide group, thiolate group, thiol group, ammonium group, and combinations thereof, and the tail group is selected from the group consisting of hydrocarbon group, fluorocarbon group, vinyl group, phenyl group, epoxide group, acrylic group, acrylate group, hydroxyl group, and combinations thereof. The composite product according to claim 16.

Description

Cross-reference of Related Applications This application claims priority to PCT application number PCT/US2019/065978 filed on 12 December 2019, and claims the benefit of U.S. Provisional Patent Applications No. 62/989,092 filed on 13 March 2020, No. 62/989,150 filed on 13 March 2020, No. 63/038,642 filed on 12 June 2020, No. 63/038,693 filed on 12 June 2020, and No. 63/039,965 filed on 16 June 2020, all of which are incorporated herein by reference in their entirety. Technical Field The present invention relates to the functionalization of textile surfaces using ceramic surface modifiers, particularly binderless ceramics such as metal oxides and/or metal hydroxide ceramics, or chemical conversion coatings on textile surfaces to provide functional benefits compared to individual or non-functionalized layers, as well as aggregates of layers of such materials. Functionalizing textile surfaces provides desired benefits in terms of textile performance compared to non-functionalized textile layers. A composite of layers capable of providing multiple benefit characteristics to a single system or product is desirable, as these may offer additional benefits when compared to composites of individual functional or non-functionalized layers. Furthermore, desirable operating characteristics can be enhanced by forming a composite through the aggregation of individual functional layers. This invention provides an aggregate of functional and structural layers of a material, and/or layers possessing other beneficial properties. The functional layer may contain a ceramic material on a substrate such as a textile substrate. In one embodiment, the present invention provides an assembled material comprising an upper and lower surface, wherein (a) an At layer of x containing one or more functional properties (where the At layer includes the uppermost layer including the upper surface); (b) an Ab layer of y containing one or more functional properties (where the Ab layer includes the lowermost layer including the lower surface); and (c) a B layer of z containing an insulating material, structural material, or other functionally beneficial material between the At layer of x and the Ab layer of y, wherein x, y, and z have the same or different number of layers, and the At layer and/or the Ab layer may each contain a ceramic material such as a binderless ceramic, for example, a binderless porous ceramic material, on the substrate, and the ceramic materials on each At layer and/or each Ab layer are the same or different. In one embodiment, at least one At layer contains a ceramic material such as a binderless ceramic, for example, a binderless porous ceramic material, on the substrate. In another embodiment, at least one Ab layer includes a ceramic material on the substrate, such as a binderless ceramic, e.g., a binderless porous ceramic material. In yet another embodiment, at least one At layer and at least one Ab layer each include a ceramic material on the substrate, such as a binderless ceramic, e.g., a binderless porous ceramic material. In some embodiments, the top and/or bottom surfaces include a ceramic material, such as a binderless ceramic, e.g., a binderless porous ceramic material. In some embodiments, the Ab layer and/or At layer include a plurality of functional (e.g., aesthetic and/or performance-related) properties. In another embodiment, the present invention provides an assembly of materials including an upper surface and a lower surface, comprising: (a) an A layer of x layers of a material having one or more functional properties (wherein the A layer includes the uppermost layer including the upper surface, and each of the A layers includes a binderless ceramic, such as a binderless porous ceramic material, on a substrate); and (b) a B layer of z layers of an insulating material, structural material, or other functionally beneficial material (wherein the B layer includes the lowermost layer including the lower surface), wherein x and z have the same or different number of layers. In some embodiments, the assembly does not include an A b layer. In another embodiment, the present invention provides an assembly of materials including an upper and lower surface, comprising: (a) an At layer of x layers of material having one or more functional properties (where the At layer includes the uppermost layer including the upper surface); and (b) an Ab layer of y layers of material having one or more functional properties (where the Ab layer includes the lowermost layer including the lower surface), wherein the At layer and the Ab layer each contain a ceramic material on the substrate, such as a binderless ceramic, for example, a binderless porous ceramic material, and the ceramic material on the At layer is different from the ceramic material on the Ab layer, and x and y are the same or different. In some embodiments, the assembly does not include a B layer. In one embodiment, at least one At layer contains a ceramic material